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A method for producing a double jersey fabric on a double jersey, single
jacquard circular knitting machine includes steps of knitting a front
side of the fabric on a cylinder (C) and knitting the rear side of the
fabric on a dial (D) of the machine, knitting a base yarn on a rear side
of the fabric, except for connecting points where the base yarn is
knitted on the front side of the fabric. The method additionally includes
steps of inserting a pattern yarn before a start of a pattern unit, which
is produced using the pattern yarn, knitting the pattern yarn on the
front side of the fabric in the pattern unit and cutting off the pattern
yarn after the pattern unit.

51. A method for knitting a double jersey knitted fabric on a double
jersey, single jacquard circular knitting machine, wherein the fabric has
a front side and a rear side, the method comprising the steps of:
knitting the front side of the fabric on a cylinder (C) of the circular
knitting machine; knitting the rear side of the fabric on a dial (D) of
the circular knitting machine; knitting a base yarn on the rear side of
the fabric, except for connecting points, where a base yarn is knitted on
the front side of the fabric; inserting a pattern yarn before a start of
a pattern unit, wherein the pattern unit is produced using the pattern
yarn; knitting the pattern yarn on the front side of the fabric in the
pattern unit; and cutting off the pattern yarn after the pattern unit.

52. A method for knitting a double jersey knitted fabric on a double
jersey, single jacquard circular knitting machine, wherein the fabric has
a front side and a rear side, the method comprising the steps of:
knitting the front side of the fabric on a cylinder (C) of the circular
knitting machine; knitting the rear side of the fabric on a dial (D) of
the circular knitting machine; knitting a base yarn on the rear side of
the fabric, except for connecting points, where a base yarn is knitted on
the front side of the fabric; inserting a pattern yarn before a start of
a pattern unit, wherein the pattern unit is produced using the pattern
yarn; knitting the pattern yarn on both the front side and the rear side
of the fabric in the pattern unit; and cutting off the pattern yarn after
the pattern unit is produced using the pattern yarn.

53. A method for knitting a double jersey knitted fabric on a double
jersey, single jacquard circular knitting machine, wherein the fabric has
a front side and a rear side, the method comprising the steps of:
knitting the front side of the fabric on a cylinder (C) of the circular
knitting machine; knitting the rear side of the fabric on a dial (D) of
the circular knitting machine; knitting a base yarn on the rear side of
the fabric, except for connecting points, where the base yarn is knitted
on the front side of the fabric; either: knitting a first pattern yarn
only on the front side of the fabric in a first pattern unit produced
using the first pattern yarn, including having the first pattern yarn
floating between the front side and the rear side of the fabric in a
second pattern unit preceding the first pattern unit, and a third pattern
unit following the first pattern unit, wherein the second pattern unit
and the third pattern unit are not produced using the first pattern yarn;
or inserting the first pattern yarn before the first pattern unit
produced using the first pattern yarn, knitting the first pattern yarn on
the front side in the first pattern unit, and cutting off the first
pattern yarn after the first pattern unit; inserting a second pattern
yarn before the second pattern unit produced using the second pattern
yarn; knitting the second pattern yarn on both the front side and the
rear side of the fabric in the second pattern unit; knitting the second
pattern yarn on the rear side of the fabric in the first pattern unit;
knitting the second pattern yarn on both the front side and on the rear
side of the fabric in the third pattern unit; cutting off the second
pattern yarn after the third pattern unit; and knitting a third pattern
yarn in an identical manner to the first pattern yarn.

54. A method for knitting a double jersey knitted fabric on a double
jersey, single jacquard circular knitting machine, wherein the fabric has
a front side and a rear side and comprises a first pattern yarn, a second
pattern yarn and a binding yarn, the method comprising the steps of:
knitting the front side of the fabric on a cylinder (C) of the circular
knitting machine; knitting the rear side of the fabric on a dial (D) of
the circular knitting machine; knitting a base yarn on the rear side of
the fabric, except for connecting points, where the base yarn is knitted
on the front side of the fabric; inserting a binding yarn at a position
of 1 to 50 stitches before a start of a first pattern unit; knitting the
binding yarn on the front side of the fabric before the start of the
first pattern unit for the abovementioned number of stitches, together
with the first pattern yarn that is knitted on the front side of the
fabric before the start of the first pattern unit in a preceding pattern
unit; inserting the first pattern yarn at the start of the first pattern
unit and cutting off the second pattern yarn; knitting the binding yarn
on the front side of the fabric after the start of the first pattern
unit, together with the second pattern yarn knitted on the front side of
the fabric in the preceding pattern unit; knitting the binding yarn on
the front side of the fabric after the end of the first pattern unit for
the abovementioned number of stitches, together with the first pattern
yarn knitted on the front side of the fabric after the end of first
pattern unit; and cutting off the binding yarn, such that loose ends of
the binding yarn are between 0.1 cm to 5 cm long.

55. A method for knitting a double jersey knitted fabric having a front
side, a rear side, a base yarn, and at least one of: a first pattern
yarn, a second pattern yarn and a third pattern yarn, on a double jersey,
double jacquard circular knitting machine configured with a cylinder (C)
and a dial (D), wherein needles of the cylinder (C) are operated to knit
the front side of the fabric and wherein needles of the dial (D) are
operated to knit the rear side of the fabric, the method comprising the
steps of: knitting the base yarn on the rear side of the fabric, except
for connecting points, where the base yarn is knitted on the front side
of the fabric; inserting the first pattern yarn at a position of 1 to 50
stitches before a start of a pattern unit that is produced using the
first pattern yarn and is knitted on the rear side of the fabric before a
start of the pattern unit for the abovementioned number of stitches;
subsequently knitting the first pattern yarn on the front side of the
fabric in the pattern unit; knitting the first pattern yarn on the rear
side of the fabric after the pattern unit for 1 to 50 stitches after an
end of the pattern unit; and subsequently cutting off the first pattern
yarn.

56. The method of claim 55, wherein the second pattern yarn and the third
pattern yarn are knitted in and around the second pattern unit and the
third pattern units, in a similar manner as that of the first pattern
unit produced using the first pattern yarn.

57. A fabric produced by the method according to claim 51.

58. A method for knitting a double jersey knitted fabric on a double
jacquard circular knitting machine, wherein the fabric has a front side,
a rear side, a base yarn, a mechanical yarn and a pattern yarn, the
method comprising the steps of: knitting the pattern yarn on the front
side of the fabric; inserting the mechanical yarn at a position of 1 to
50 stitches before a start of a mechanical unit produced using the
mechanical yarn; knitting the mechanical yarn on the rear side of the
fabric before the start of the mechanical unit with the abovementioned
number of stitches, together with the base yarn; knitting the mechanical
yarn on the rear side of the fabric in the mechanical unit, except for
connecting points where the mechanical yarn is knitted on the front side
of the fabric; knitting the mechanical yarn on the rear side of the
fabric after the mechanical unit produced using the respective mechanical
yarn for 1 to 50 stitches, together with the base yarn; and subsequently
cutting off the mechanical yarn.

59. The method according to claim 58, further comprising: inserting a
second pattern yarn at a position of 1 to 50 stitches before a start of a
pattern unit produced using the second pattern yarn and knitted on the
rear side of the fabric before a start of the pattern unit for the
abovementioned number of stitches; subsequently knitting second pattern
yarn on the front side of the fabric in the pattern unit; knitting the
second pattern yarn on the rear side of the fabric after the pattern unit
for 1 to 50 stitches after the end of the pattern unit; and subsequently
cutting off the second pattern yarn.

60. A fabric produced by the method according to claim 58.

61. A double jersey knitted fabric, comprising: a front side; a rear
side; a base yarn knitted on the rear side of the fabric, except for
connecting points, where the base yarn is knitted on the front side of
the fabric; and a pattern yarn inserted before a start of a pattern unit
produced using the pattern yarn; wherein the pattern yarn is knitted on
the front side of the fabric in the pattern unit produced using the
pattern yarn; and wherein the pattern yarn is cut off after the pattern
unit produced using the pattern yarn.

62. A double jersey knitted fabric, comprising: a front side; a rear
side; a base yarn knitted on the rear side of the fabric, except for
connecting points, where the base yarn is knitted on the front side of
the fabric; and a pattern yarn; wherein the pattern yarn is inserted
before a start of a pattern unit produced using the pattern yarn; wherein
the pattern yarn is knitted on both the front side and the rear side of
the fabric in the pattern unit; and wherein the pattern yarn is cut off
after the pattern unit produced using the pattern yarn.

63. A double jersey knitted fabric, comprising: a front side; a rear
side; a base yarn knitted on the rear side of the fabric, except for
connecting points, where the base yarn is knitted on the front side of
the fabric; a first pattern yarn; a second pattern yarn; and a third
pattern yarn; wherein the first pattern yarn is knitted only on the front
side of the fabric in a first pattern unit produced using the first
pattern yarn; and wherein the first pattern yarn either: floats between
the front side and the rear side of the fabric in a second pattern unit
preceding the first pattern unit and in a third pattern unit following
the first pattern unit, wherein the second pattern unit and the third
pattern unit are not produced using the first pattern yarn; or is
inserted before the first pattern unit produced using the first pattern
yarn, is knitted on the front side in the first pattern unit, and is cut
off after the first pattern unit; wherein the second pattern yarn is
inserted before the first pattern unit produced using the second pattern
yarn; wherein the second pattern yarn is knitted on both the front side
and the rear side of the fabric in the second pattern unit; wherein the
second pattern yarn is knitted on the rear side of the fabric in the
first pattern unit; wherein the second pattern yarn is knitted on both
the front side and on the rear side of the fabric in the third pattern
unit; wherein the second pattern yarn is cut off after the third pattern
unit; wherein the third pattern yarn is knitted in an identical manner to
the knitting of the first pattern yarn.

64. A double jersey knitted fabric, comprising: a front side; a rear
side; a base yarn knitted on the rear side of the fabric, except for
connecting points, where the base yarn is knitted on the front side of
the fabric; a first pattern yarn; a second pattern yarn; and a binding
yarn; wherein the binding yarn is inserted at a position of 1 to 50
stitches before a start of a pattern unit; wherein the binding yarn is
knitted on the front side of the fabric before the start of the pattern
unit for the abovementioned number of stitches, together with the first
pattern yarn which is knitted on the front side of the fabric before the
start of the pattern unit; wherein the second pattern yarn is inserted at
the start of pattern unit and the first pattern yarn is cut off; wherein
the binding yarn is knitted on the front side of the fabric after the
start of the pattern unit, together with the second pattern yarn knitted
on the front side of the fabric in the pattern unit; wherein the binding
yarn is knitted on the front side of the fabric after the end of the
pattern unit for the abovementioned number of stitches, together with the
second pattern yarn knitted on the front side of the fabric after the end
of the pattern unit; and wherein the binding yarn and the first pattern
yarn are subsequently cut off so that loose ends of the binding yarn and
the first pattern yarn are between 0.1 to 5 cm long.

65. A double jersey knitted fabric, comprising: a front side; a rear
side; a base yarn knitted on the rear side of the fabric, except for
connecting points, where the base yarn is knitted on the front side of
the fabric; and at least one of a first pattern yarn, a second pattern
yarn or a third pattern yarn; wherein the first pattern yarn is inserted
at a position of 1 to 50 stitches before a start of a pattern unit
produced using the pattern yarn and is knitted on the rear side of the
fabric before a start of a first pattern unit for the abovementioned
number of stitches; wherein the first pattern yarn is subsequently
knitted on the front side of the fabric in the first pattern unit;
wherein the first pattern yarn is knitted on the rear side of the fabric
after the first pattern unit for 1 to 50 stitches after an end of the
first pattern unit; and wherein the first pattern yarn is subsequently
cut off.

66. The double jersey knitted fabric of claim 65, wherein a second
pattern unit and a third pattern yarn are produced using the second
pattern yarn and the third pattern yarn, respectively, in a manner by
which the first pattern unit is knitted using first pattern yarn.

68. A fabric knitted on a double jersey, double jacquard circular
knitting machine, the fabric comprising: a front side; a near side; a
base yarn; a mechanical yarn; and a pattern yarn; wherein the pattern
yarn is knitted on the front side of the fabric; wherein the mechanical
yarn is inserted at a position of 1 to 50 stitches before the start of a
mechanical unit produced using the mechanical yarn; wherein the
mechanical yarn is knitted on the rear side of the fabric before a start
of the mechanical unit for the abovementioned number of stitches,
together with the base yarn; wherein the mechanical yarn is knitted on
the rear side of the fabric in the mechanical unit, except for connecting
points where the mechanical yarn is knitted on the front side of the
fabric; wherein the mechanical yarn is knitted on the rear side of the
fabric after the mechanical unit produced using the respective mechanical
yarn, for 1 to 50 stitches, together with the base yarn; and wherein the
mechanical yarn is subsequently cut off.

69. The fabric according to claim 68, further comprising a second pattern
yarn that is inserted at a position of 1 to 50 stitches before a start of
a pattern unit produced using the second pattern yarn and is knitted on
the rear side of the fabric before the start of the pattern unit for the
abovementioned number of stitches; wherein the second pattern yarn is
subsequently knitted on the front side of the fabric in the pattern unit;
wherein the second pattern yarn is knitted on the rear side of the fabric
after the pattern unit for 1 to 50 stitches after the end of the pattern
unit; and where the second pattern yarn is subsequently cut off.

70. A mattress tick comprising the fabric according to claim 61.

71. A double jersey, double jacquard circular knitting machine,
comprising: a cylinder (C) provided with a needle selector; a dial (D)
provided with a needle selector; and one or more yarn selection
mechanisms for the needles on the dial (D); wherein the circular knitting
machine is configured for knitting a double jersey knitted fabric
according to claim 61; wherein each yarn selection mechanism is provided
with a yarn-cutting device; and wherein each yarn selection mechanism is
configured to perform a yarn change at any position in the double jersey
knitted fabric.

72. A double jersey, single jacquard circular knitting machine,
comprising: a cylinder (C) provided with a needle selector and a dial
(D); one or more yarn selection mechanisms for needles on the dial;
wherein the circular knitting machine is configured for knitting a double
jersey knitted fabric according to claim 61; wherein each yarn selection
mechanism is provided with a yarn-cutting device; and wherein each yarn
selection mechanism is configured to perform a yarn change at any
position in the double jersey knitted fabric.

Description

TECHNICAL FIELD

[0001] The present invention relates to a double jersey fabric, a method
for producing a double jersey fabric, a circular knitting machine for
knitting a double jersey knitted fabric, and the use of a circular
knitting machine for producing a double jersey fabric. More particularly,
the present invention relates to efficient use of material and improved
productivity in the context of double jersey knitted fabrics by making
use of yarn selection.

TECHNOLOGICAL BACKGROUND OF THE INVENTION

[0002] A double jersey knitted fabric (also referred to as double jersey
knitwear) is a classic knitted fabric which is currently knitted on
circular knitting machines. A double jersey circular knitting machine is
generally provided with a cylinder and a dial, with the dial being
positioned just above the cylinder. Generally, both the cylinder and the
dial are each provided with needles. Usually, the needles of the cylinder
are intended for knitting the "aesthetic" front side of the fabric and
the needles of the dial are intended for knitting the "technical" rear
side of the fabric. Filler or lay-in threads are often inserted between
the front side and the rear side of the knitwear in order to add volume
to the fabric. This is particularly useful when the double jersey
knitwear is being used as mattress tick.

[0003] Often, a large variety of yarns is used in prior-art double jersey
knitted fabrics. These yarns may be, for example, colourful, aesthetic
yarns, but may also be mechanical yarns which are used for their specific
mechanical properties, for example their elasticity, antistatic capacity
and moisture-wicking capacity. In order to produce colour variations and
variations in mechanical properties in various areas of a double jersey
knitted fabric, not all yarns are knitted everywhere on the front side or
the rear side of the double jersey knitted fabric. In those regions where
a certain yarn is not knitted on the "aesthetic" front side of the
fabric, the yarn is either knitted unnecessarily on the rear side of the
fabric or the yarn floats and is inserted between the front and rear
sides of the knitted fabric, optionally together with lay-in yarns.

[0004] However, inserting such yarns between the front side and rear side
has the drawback that such floating yarns are difficult to control, in
particular when they float across large distances. In order to overcome
this challenge, these yarns may, as mentioned above, be anchored in a
"technical" pattern on the non-visible, technical rear side of the double
jersey knitted fabric. This technique is described in EP1975294. However,
if the yarns are expensive and if the expensive yarn is only knitted in a
small pattern on the front side, a large part of the yarn is wasted since
only a small fraction of the yarn is visible. The present invention
provides a cost-saving solution for this challenge without loss of
quality.

[0005] Although the general technology (called plating) of inserting a
pattern yarn before a certain pattern, and cutting said yarn after the
pattern is completed is known for single Jersey fabrics such as socks, to
our knowledge said technology has not been used to produce double Jersey
fabrics. Although yarn selectors such as stripers are well known in the
circular knitting field, they have to our knowledge never been used on
double jacquard circular knitting machines, to select and deselect yarns
to be knitted in a pattern on a double Jersey fabric.

SUMMARY

[0006] In one aspect, the present invention comprises a method for
knitting a double jersey knitted fabric (100) on a double jersey, single
jacquard circular knitting machine: [0007] which has a front side (600)
and a rear side (500); [0008] which comprises one or more base yarns
(308) which are substantially knitted on the rear side (500), except for
a few connecting points which are knitted on the front side (600); [0009]
which comprises one or more pattern yarns (302, 304 or 306);
characterized in that [0010] the abovementioned pattern yarn is inserted
before the start of a pattern unit (400) which is produced using the
respective pattern yarn (302, 304 or 306); [0011] said pattern yarn is
subsequently knitted on the front side (600) of the fabric in the pattern
unit (400); [0012] said pattern yarn is cut off after the pattern unit.

[0013] In a further aspect, the present invention comprises a method for
knitting a double jersey knitted fabric (100): [0014] which has a front
side (600) and a rear side (500); [0015] which comprises one or more base
yarns (308) which are substantially knitted on the rear side (500),
except for a few connecting points which are knitted on the front side
(600); [0016] which comprises one or more pattern yarns (302, 304 or
306); [0017] which is knitted on a double jersey, double jacquard
circular knitting machine which has a cylinder (C) and a dial (D), in
which the needles of the cylinder (C) are intended for knitting the front
side (F) of the fabric and the needles of the dial (D) are intended for
knitting the rear side (B) of the fabric; characterized in that [0018]
the abovementioned pattern yarn (302, 304 or 306) is inserted at a
position of 1 to 50, preferably 1 to 20, more preferably 1 to 10 and most
preferably 1, 2, or 3 stitches before the start of a pattern unit (400)
which is produced using the respective yarn (302, 304 or 306) and is
knitted on the rear side of the fabric (100) before the start of the
pattern unit (400) for the abovementioned number of stitches; [0019] said
pattern yarn is subsequently knitted on the front side (600) of the
fabric in the pattern unit (400); [0020] said pattern yarn is knitted on
the rear side (500) of the fabric (100) after the pattern unit (400) for
1 to 50, preferably 1 to 20, more preferably 1 to 10 and most preferably
1, 2 or 3 stitches after the end of a pattern unit (400); and [0021] said
pattern yarn (302, 304 or 306) is subsequently cut off.

[0022] In a further aspect, the present invention comprises a method for
knitting a double jersey knitted fabric on a double jacquard circular
knitting machine: [0023] which has a front side and a rear side; [0024]
which comprises one or more mechanical yarns which are knitted on the
rear side and/or on the front side of the fabric; characterized in that
[0025] the abovementioned mechanical yarn (310) is inserted at a position
of 1 to 50, preferably 1 to 20, more preferably 1 to 10 and most
preferably 1, 2 or 3 stitches before the start of a mechanical unit (900)
or a mechanical pattern which is produced using the respective mechanical
yarn; [0026] said mechanical yarn (310) is knitted on the rear side of
the fabric before the start of the mechanical unit (900) with the
abovementioned number of stitches, together with a second yarn (e.g.
another mechanical yarn or a base yarn) which was used to produce a
preceding mechanical unit; [0027] said mechanical yarn (310) in the
mechanical unit (900) is knitted on the rear side and/or on the front
side of the fabric; [0028] said mechanical yarn (310) is knitted on the
rear side of the fabric after the mechanical unit (900) which was
produced using the respective mechanical yarn for 1 to 50, preferably 1
to 20, more preferably 1 to 10 and most preferably 1, 2 or 3 stitches,
together with the yarn (e.g. base yarn 308) which is used to produce a
subsequent mechanical unit (902); and [0029] said mechanical yarn (310)
is subsequently cut off.

[0030] In a further aspect, the present invention comprises a double
jersey knitted fabric [0031] which has a front side and a rear side;
[0032] which comprises one or more base yarns which are knitted both on
the front side and on the rear side; [0033] which comprises one or more
pattern yarns; characterized in that [0034] the pattern yarn is inserted
at a position of 1 to 50, preferably 1 to 20, more preferably 1 to 10 and
most preferably 1, 2 or 3 stitches before the start of a pattern unit
which is produced using the respective yarn and is knitted on the rear
side of the fabric before the start of the pattern unit for the
abovementioned number of stitches; [0035] said pattern yarn is
subsequently knitted in a pattern unit on the front side of the fabric;
[0036] said pattern yarn is knitted after on the rear side of the fabric
a pattern unit for 1 to 50, preferably 1 to 20, more preferably 1 to 10
and most preferably 1, 2 or 3 stitches after the end of a pattern unit;
and [0037] said pattern yarn is subsequently cut off.

[0038] In a further aspect, the present invention comprises a double
jersey, double jacquard circular knitting machine [0039] which
comprises a cylinder (C) and a dial (D); [0040] which is provided with
one or more yarn selection mechanisms; in which the double jersey, double
jacquard circular knitting machine is suitable for knitting a double
jersey knitted fabric as described herein. Such a knitting machine
comprises a cylinder and a dial provided with needles each separately
driven by an electronical pattern controlling mechanism (also called
jacquard mechanism), wherein the needles of the cylinder are provided for
knitting the front of the fabric, and the needles of the dial are
provided for knitting the back of the fabric. Said knitting machine is
more particularly suited for knitting a double jersey knitted fabric
which has a front side and a rear side; which comprises one or more base
yarns which may be knitted both on the front side and on the rear side;
which comprises one or more pattern yarns; in which the pattern yarn is
inserted at a position of 1 to 50, preferably 1 to 20, more preferably 1
to 10 and most preferably 1, 2 or 3 stitches before the start of a
pattern unit which is produced using the respective yarn and is knitted
on the rear side of the fabric before the start of the pattern unit for
the abovementioned number of stitches; in which said pattern yarn is
subsequently knitted on the front side of the fabric in the pattern unit;
in which said pattern yarn is knitted on the rear side of the fabric
after the pattern unit for 1 to 50, preferably 1 to 20, more preferably 1
to 10 and most preferably 1, 2 or 3 stitches after the end of the pattern
unit; and in which said pattern yarn is subsequently cut off; said
machine being characterized in that: [0041] each yarn selection mechanism
is provided with a yarn-cutting device; [0042] each yarn selection
mechanism is configured to be able to perform a yarn change at any
position in the double jersey knitted fabric.

[0043] In a further aspect, the present invention comprises a double
jersey, single jacquard circular knitting machine [0044] which
comprises a cylinder (C) and a dial (D) [0045] which is provided with one
or more yarn selection mechanisms which is suitable for knitting a double
jersey knitted fabric as described herein and more particularly for
knitting a double jersey knitted fabric which has a front side (600) and
a rear side (500); which comprises one or more base yarns (308) which are
knitted on the rear side (500) except for some connecting points (240,
242) which are knitted on the front side (600); which comprises one or
more pattern yarns (302, 304, 306); in which an abovementioned pattern
yarn is inserted before the start of a pattern unit (400) which is
produced using the respective yarn (302, 304, 306); in which the said
pattern yarn is subsequently knitted on the front side (600) of the
fabric in the pattern unit (400); in which said pattern yarn is cut off
after the pattern unit; characterized in that: [0046] each yarn selection
mechanism is provided with a yarn-cutting device; [0047] each yarn
selection mechanism is configured to be able to perform a yarn change at
any position in the double jersey knitted fabric.

[0048] The invention hence provides in the following items:

[0049] Item 1: A method for knitting a double jersey knitted fabric (100)
on a double jersey, single jacquard circular knitting machine, wherein
the fabric has a front side (600) and a rear side (500), comprising the
following steps; [0050] knitting the front side (600) of the fabric
(100) on the cylinder (C) and knitting the rear side (500) of the fabric
(100) on the dial (D) of said machine; [0051] knitting a base yarn (308)
on the rear side (500) of the fabric (100), except for connecting points
(240, 242) where the base yarn (308) is knitted on the front side (600)
of the fabric (100); characterized in that the method comprises the
following additional steps: [0052] inserting a pattern yarn (302) before
the start of a pattern unit (400) which is produced using the respective
pattern yarn (302); [0053] knitting the pattern yarn (302) on the front
side (600) of the fabric in the pattern unit (400); [0054] cutting off
the pattern yarn (302) after the pattern unit (400).

[0055] In this way, a saving in expensive pattern yarns is achieved
without loss of quality of the knitted fabric.

[0056] The term "double jersey knitted fabric" or "double jersey
knitwear", as used herein, is defined as a knitted fabric which is
knitted on a circular knitting machine, in which the circular knitting
machine is provided with a cylinder and a dial which is situated just
above the cylinder. Both the cylinder and the dial are provided with
needles. The needles of the cylinder are intended for knitting the front
side of the fabric. The needles of the dial are intended for knitting the
rear side of the fabric. A double jersey knitted fabric comprises one or
more yarns which are knitted on both the front side of the knitted fabric
and on the rear side of the knitted fabric, thus forming a connection
between the front and rear side of the knitted fabric. Usually, filler
threads are added between the dial and the cylinder to add volume to the
double jersey knitted fabric, for example when the double jersey knitted
fabric is used as mattress tick, but this is not compulsory.

[0057] The term "base yarn", as used herein, refers to the yarns which are
typically used for the technical rear side of the fabric or the knitted
fabric. They are strong threads which form the basis of the knitted
fabric and on which the patterns are recorded.

[0058] The term "binding yarn", as used herein, refers to a yarn which is
inserted to anchor loose threads. Often, the binding yarn is slightly
thinner than normal base or pattern yarn and is knitted together with
these yarns in order to reinforce the transition zone between two types
of yarns in successive patterns.

[0059] The term "stitch", as used herein, may also refer to a tuck stitch
(French: "une charge"). Tuck stitches may be used in particular to anchor
pattern yarns on the rear side of a knitted fabric. However, anchoring by
means of tuck stitches is less efficient than anchoring by means of
stitches; tuck stitches are less well fixed than stitches. This may be
remedied, for example, by using a larger number of anchoring points when
using tuck stitches compared to using stitches for anchoring.

[0060] The term "front side" of a double jersey knitted fabric is
understood to refer to the aesthetic side of the knitted fabric which is
visible to the user during normal use.

[0061] The term "rear side" of a double jersey knitted fabric is
understood to refer to the technical side of the knitted fabric which is
invisible to a user during normal use, but which gives the fabric the
desired mechanical properties.

[0062] The term "pattern unit" is understood to mean a piece of a double
jersey knitted fabric in which a certain pattern yarn is knitted on the
front side of the fabric. The term "pattern yarn" refers to a yarn which
is used to form a pattern in the knitted fabric. This may be a colour
pattern or a pattern having a different quality, having a different feel
or a different thickness. Usually, the pattern yarn is a yarn of a
relatively expensive quality. If reference is made to one pattern unit in
the aspects and claims, then this obviously does not exclude the presence
of further identical or different pattern units in the fabric.

[0063] The term "pattern unit" also includes the term "mechanical unit"
which forms a pattern made with a mechanical yarn which imparts certain
mechanical properties to the fabric.

[0064] The term "mechanical yarn" is understood to mean a yarn which
imparts a certain mechanical property to the knitted fabric. Examples are
elastic, antistatic or moisture-wicking yarns. Pattern units or
mechanical units may thus also be made of yarns which impart a different
property to the knitted fabric, for example antistatic or
moisture-wicking yarns for knitting antistatic pattern units or
moisture-wicking yarns for use in certain zones of the mattress tick. One
knitted fabric may comprise different pattern units. Pattern units and/or
mechanical units may alternate and/or repeat.

[0065] The term "double jersey, single jacquard circular knitting machine"
is understood to mean a circular knitting machine which is suitable for
knitting double jersey fabrics and which comprises a single needle
selection mechanism.

[0066] Item 2: A method for knitting a double jersey knitted fabric on a
double jersey, single jacquard circular knitting machine, wherein the
fabric has a front side (600) and a rear side (500), comprising the steps
of: [0067] knitting the front side (600) of the fabric (100) on the
cylinder (C) and knitting the rear side (500) of the fabric (100) on the
dial (D) of the machine; [0068] knitting a base yarn (308) on the rear
side (500) of the fabric (100), except for connecting points (240, 242)
where the base yarn (308) is knitted on the front side of the fabric;
characterized in that the method additionally comprises the following
steps: [0069] Inserting a pattern yarn (304) before the start of a
pattern unit (400) which is produced using the respective yarn (304);
[0070] knitting the pattern yarn (304) on both the front side (600) and
the rear side (500) of the fabric in the pattern unit (400); [0071]
cutting off the pattern yarn (304) after the pattern unit (400) which is
produced using said yarn.

[0072] In this way, a saving in expensive pattern yarns is achieved
without the loss of quality of the knitted fabric.

[0073] Item 3: A method for knitting a double jersey knitted fabric on a
double jersey, single jacquard circular knitting machine, wherein the
fabric has a front side (600) and a rear side (500), a first pattern yarn
(302), a second pattern yarn (304) and a third pattern yarn (306),
comprising the following steps: [0074] knitting the front side (600) of
the fabric (100) on the cylinder (C) and knitting the rear side (500) of
the fabric (100) on the dial (D) of said machine; [0075] knitting a base
yarn (308) on the rear side (500) of the fabric (100), except for
connecting points (240, 242) wherein the base yarn (308) is knitted on
the front side of the fabric; characterized in that the method further
comprises the steps of: [0076] knitting a first pattern yarn (302) only
on the front side (600) of the fabric in a first pattern unit (400)
produced using said first pattern yarn (302); [0077] having the first
pattern yarn (302) floating between the front side (600) and the rear
side (500) of the fabric in the zones which are not produced using the
first pattern yarn (302), in particular a second pattern unit (401)
preceding the first pattern unit (400) and a third pattern unit (402)
following the first pattern unit (400); or [0078] inserting the first
pattern yarn (302) before the first pattern unit (400) which is produced
using the first pattern yarn (302), knitting said first pattern yarn
(302) on the front side in the first pattern unit (400), and cutting off
said first pattern yarn (302) after said first pattern unit; [0079]
inserting a second pattern yarn (304) before the second pattern unit
(401) which is produced using the second pattern yarn (304); [0080]
knitting the second pattern yarn (304) on both the front side (600) and
the rear side (500) of the fabric in the second pattern unit (401);
[0081] knitting the second pattern yarn (304) on the rear side (500) of
the fabric (100) in the first pattern unit (400); [0082] knitting the
second pattern yarn (304) on both the front side (600) and on the rear
side (500) of the fabric (100) in the third pattern unit (402); [0083]
cutting off the second pattern yarn (304) after the third pattern unit
(402); [0084] knitting a third pattern yarn (306) in an identical manner
to the first pattern yarn (302).

[0085] In this way, a saving in expensive pattern yarns is achieved
without loss of quality of the knitted fabric.

[0086] In some embodiments, the pattern yarns are secured in the fabric by
the base yarn. As the single Jacquard circular knitting machine does not
allow automatic selection of the needles in the dial, the pattern yarn
cannot be secured by means of a few stitches on the rear side of the
fabric. By increasing the length of the ends of the pattern yarn
slightly, for example from 1 cm to approximately 2.5 or 5 cm, these will
be secured in the knitted fabric by means of friction with the rest of
the fabric.

[0087] In some embodiments, the pattern yarns (302, 304, 306) are secured
specifically at the start and end of a pattern unit (400) by means of one
or more stitches (240) on the front side of the fabric using a base yarn
(308). A specific embodiment of this concept is illustrated in FIG. 7 and
is described in one of the specific embodiments which have been added at
the end of this document.

[0088] Item 4: The method according to any one of items 1 to 3, in which,
in addition, a binding yarn (312) is knitted in on the cylinder (C),
together with the respective pattern yarns (302, 304, 306) on the front
side (600) of the fabric (100).

[0089] In this way, a saving in expensive pattern yarns is achieved,
without loss of quality of the knitted fabric.

[0090] The length and the loose ends and the number of stitches with which
the binding yarn is knitted together with the pattern yarn is determined
by means of an assessment between costs and strength of the mechanical
anchoring.

[0091] A large number of stitches increases the strength of the mechanical
anchoring, but also increases the costs. In general, a relatively low
number of connecting stitches is preferred, for example fewer than five
stitches, because this already provides sufficient mechanical anchoring
at low costs. However, when anchoring, for example, very smooth yarns, a
larger number of stitches may be optimum.

[0092] Long loose ends may also benefit the mechanical anchoring. However,
an assessment also has to be made of the costs and the strength of the
mechanical anchoring. In addition, there is a risk of the loose ends
showing through the front side of the knitted fabric if highly
contrasting colours are used. It is therefore preferred to use relatively
short ends in the case of highly contrasting colours.

[0093] In a further embodiment, the present invention describes the method
as described in one of the items 1 to 3, in which, in addition, a binding
yarn (312) is knitted in on the cylinder (C), together with the
respective pattern yarns (302, 304, 306) on the front side (600) of the
fabric (100).

[0094] Alternatively, the binding yarn (312) may be knitted in completely
with the pattern yarn (302) in the pattern unit, thus obtaining a method
according to item 4, characterized in that: [0095] a binding yarn is
inserted at a position of 1 to 50, preferably 1 to 20, more preferably 1
to 10 and most preferably 1, 2 or 3 stitches before the start of a
pattern unit; [0096] the binding yarn is knitted on the front side of the
fabric before the start of the pattern unit for the abovementioned number
of stitches, together with the yarn which is knitted on the front side of
the fabric before the start of the pattern unit; [0097] the binding yarn
is knitted on the front side of the fabric after the start of the pattern
unit, together with the yarn which is knitted on the front side of the
fabric in said pattern unit; [0098] the binding yarn is knitted on the
front side of the fabric after the end of the pattern unit for the
abovementioned number of stitches, together with the yarn which is
knitted on the front side of the fabric after the end of said pattern
unit; [0099] the binding yarn is subsequently cut off;

[0100] so that the loose ends of the binding yarns are 0.1 to 5 cm long,
are preferably 0.5 cm to 2.5 cm long, and are most preferably
approximately 1 cm long.

[0101] Connecting pattern yarns and binding yarns together by knitting is
currently done by means of plating technology (French: vanisage). In this
way, pattern units on the front side of a double jersey knitted fabric
are connected to one another. In an analogous manner, mechanical yarns of
different mechanical units can be connected to each other by means of
binding yarns.

[0102] In this way, the yarns which are used to produce adjacent pattern
units are efficiently anchored to one another at the transition between
the respective pattern units.

[0103] Item 5: A method for knitting a double jersey knitted fabric (100)
on a double jersey, single jacquard circular knitting machine, wherein
said fabric has a front side (600) and a rear side (500) and comprises a
first pattern yarn (302), a second pattern yarn (304) and a binding yarn
(312), comprising the steps of: [0104] knitting the front side (600) of
the fabric (100) on the cylinder (C) and knitting the rear side (500) of
the fabric (100) on the dial (D) of said machine; [0105] knitting a base
yarn (308) on the rear side (500) of the fabric (100), except for
connecting points (240) wherein the base yarn (308) is knitted on the
front side (600) of the fabric (100); characterized in that the method
further comprises the steps of: [0106] inserting the binding yarn (312)
at a position of 1 to 50, preferably 1 to 20, more preferably 1 to 10 and
most preferably 1, 2 or 3 stitches before the start of a first pattern
unit (400); [0107] knitting the binding yarn (312) on the front side of
the fabric before the start of the first pattern unit (400) for the
abovementioned number of stitches, together with the first pattern yarn
(302) which is knitted on the front side (600) of the fabric (100) before
the start of the first pattern unit (400) in a preceding pattern unit
(401); [0108] inserting the first pattern yarn (302) at the start of the
first pattern unit (400) and cutting off the second pattern yarn (304);
[0109] knitting the binding yarn (312) on the front side (600) of the
fabric (100) after the start of the first pattern unit (400), together
with the second pattern yarn (304) which is knitted on the front side of
the fabric in the preceding pattern unit (401); [0110] knitting the
binding yarn (312) on the front side of the fabric after the end of the
first pattern unit (400) for the abovementioned number of stitches,
together with the first pattern yarn (304) which is knitted (400) on the
front side (600) of the fabric (100) after the end of first pattern unit;
[0111] Cutting off the binding yarn (312), such that the loose ends of
the binding yarn (312) are 0.1 to 5 cm long, are preferably 0.5 cm to 2.5
cm long, and are most preferably approximately 1 cm long.

[0112] Item 6: A method for knitting a double jersey knitted fabric (100)
having a front side (600) and a rear side (500) and comprises a base yarn
(308, a first pattern yarn (302) and, optionally, a second pattern yarn
(304) and a third pattern yarn (306), on a double jersey, double jacquard
circular knitting machine which has a cylinder (C) and a dial (D), in
which the needles of the cylinder (C) are intended for knitting the front
side (F) of the fabric and the needles of the dial (D) are intended for
knitting the rear side (B) of the fabric, said method comprising the
steps of: [0113] knitting the base yarn (308) on the rear side (500) of
the fabric (100), except for connecting points (240) where the base yarn
(308) is knitted on the front side (600) of the fabric (100);
characterized in that: [0114] the first pattern yarn (302) is inserted at
a position of 1 to 50, preferably 1 to 20, more preferably 1 to 10 and
most preferably 1, 2 or 3 stitches before the start of a pattern unit
(400) which is produced using the respective first pattern yarn (302) and
is knitted on the rear side of the fabric (100) before the start of the
pattern unit (400) for the abovementioned number of stitches; [0115] the
first pattern yarn (302) is subsequently knitted on the front side (600)
of the fabric in the pattern unit (400); [0116] the first pattern yarn
(302) is knitted on the rear side (500) of the fabric (100) after the
pattern unit (400) for 1 to 50, preferably 1 to 20, more preferably 1 to
10 and most preferably 1, 2 or 3 stitches after the end of a pattern unit
(400); and [0117] the first pattern yarn (302) is subsequently cut off;
[0118] optionally, the second pattern yarn (304) and the third pattern
yarn (306) are knitted in a similar manner in and around the pattern
units which are produced using these respective yarns as described for
the first pattern yarn (302).

[0119] In this way, a significant amount of expensive pattern yarn is
saved, for example compared to the method described in EP1975294, because
the expensive yarns are only knitted in a pattern unit and in the
immediate vicinity of a pattern unit.

[0120] Cutting off binding yarns and pattern or mechanical yarns as
mentioned in the method described herein may be effected by any cutting
device. Preferably, such cutting devices are composed of a clamping unit
which retains the yarn to be cut and of a cutting unit which cuts the
yarn. Examples are known from the field of circular knitting machines.

[0121] The insertion of binding yarns, pattern yarns or mechanical yarns
may be effected by so-called yarn selection mechanisms or yarn selectors
(also known as stripers or yarn fingers). These finger-like devices
introduce the yarn into the knitting system in such a manner and at the
appropriate time that the yarn can be gripped by the needles of the dial
for knitting. This process is also referred to as feeding the yarn.
Examples are generally known from the field of the circular knitting
machines.

[0122] In the paragraphs below, the operation of the cutting device and
the yarn selector is illustrated for pattern yarns and mechanical yarns.
The operation is identical for binding yarns, mutatis mutandis. As a
non-limiting example the operation of the cutting device and the yarn
selector for pattern or mechanical yarns is adjusted with respect to each
other as follows:

[0123] 1) the pattern or mechanical yarn is fed to the needles by the
respective yarn selector at a position of 1 to 50, preferably 1 to 20,
more preferably 1 to 10 and most preferably 1, 2 or 3 stitches before the
start of the pattern unit, following which the yarn is first knitted in
on the rear side of the fabric by the needles of the dial for the number
of stitches mentioned, following which the yarn is knitted in by the
needles of the cylinder on the front side of the fabric to form the
pattern unit, and finally, the yarn is again knitted in by the needles of
the dial on the rear side of the fabric for the number of stitches
mentioned. Providing or feeding the yarns by the yarn selector may also
be assisted by the clamping unit or the cutting device which may clamp
the yarn before it is inserted and subsequently immediately release it,
as soon as the yarn has been caught by the needles of the dial;

[0124] 2) the yarn is subsequently taken to the cutting device by the yarn
selector and the yarn is clamped by the clamping unit and cut off by the
cutting unit. Typically, this produces a loose end having a length of
approximately 0.1 to 5 cm, preferably 0.5 cm to 2.5 cm, and most
preferably approximately 1 cm, which is inserted between the knitted
fabrics of the front and rear side.

[0125] Item 7: The method according to any one of items 1 to 6,
characterized in that the knitting process uses at least one pattern unit
comprising more than 12 needles.

[0126] By using more than 12 needles, it is possible to knit large pattern
units.

[0127] Item 8: The method according to any one of items 1 to 7,
characterized in that the fabric is a non-reversible single-sided knitted
fabric wherein the desired design is knitted on the front side of the
fabric.

[0128] Double jersey knitted fabrics according to the present invention
have a front side and a rear side. By using the rear side as the
technical side and the front side as the aesthetic side with a desired
design, it is possible to produce a plurality of effects. Thus, for
example, an area with relief fabric can be created by knitting an elastic
yarn at relatively high tension on the rear side and a non-elastic yarn
at relatively low tension on the front side.

[0129] Item 9: The method according to any one of items 1 to 8, in which
the design of the front side (F) of the fabric which is knitted comprises
at least one area of relief fabric.

[0130] In mattress ticks, relief fabric is currently being used to produce
a decorative pattern. In addition, the relatively voluminous enclosed
space in an area of relief fabric makes it soft to the touch and ensures
improved ventilation.

[0131] Item 10: The method according to any one of items 1 to 9,
characterized in that the loose ends (830, 832) of yarns are 0.1 to 5 cm
long, are preferably 0.5 cm to 2.5 cm long and are most preferably
approximately 1 cm long.

[0132] The loose ends of the pattern yarns have to have a minimum length,
for example of approximately 0.1 cm, to ensure that the yarns are
sufficiently anchored in the fabric. By contrast, the loose ends of the
yarns are most preferably not too long, for example less than
approximately 5 cm, in order to prevent wasting yarn and to prevent
anything from showing through on the front side of the fabric. Loose ends
having a length of preferably 0.5 cm to 2.5 cm, preferably of
approximately 1 cm, are a good compromise between anchoring and
preventing anything from showing through or wasting yarn.

[0133] Item 11: The method according to any one of items 1 to 10,
characterized in that the fabric is provided with one or more filler
threads which are inserted between the front side and the rear side of
the double jersey knitted fabric.

[0134] These filler threads give volume to the space between the front and
rear side of the double jersey knitted fabric, which renders the fabric
more luxurious to the touch and makes it slightly softer. In addition, it
benefits the ventilating properties of the fabric and gives the fabric a
relief effect.

[0135] Item 12: The method according to any one of items 1 to 11,
characterized in that the loose ends (830, 832) of yarns are inserted
between the rear side (500) and the front side (600) of the knitted
fabric.

[0136] Positioning the loose ends (820, 822) in this way may be
advantageous when it is undesirable for the loose ends (820, 822) to
protrude from the rear side (500) of the fabric (100). This may be the
case, for example, when the rear side (500) is subjected to a
considerable shear load. If such a shear load acts on the loose ends
(820, 822), the fabric (100) might become damaged. In addition, the loose
ends are generally not visible, or hardly at all, on the front side or
rear side of the finished fabric in this way.

[0137] Surprisingly, the inventors have discovered that a method according
to the present invention is highly suitable for knitting mattress ticks:

[0138] Item 13: The invention hence encompasses a method according to any
one of items 1 to 12 for knitting a mattress tick.

[0139] Item 14: The invention further encompasses a fabric produced by the
method according to any one of items 1 to 13.

[0140] In some embodiments, the fabric comprises more than two pattern
yarns.

[0141] By using, for example, several yarns with different colours, it is,
for example, possible to produce colourful patterns in the fabric.

[0142] Item 15: A method for knitting a double jersey knitted fabric on a
double jacquard circular knitting machine, wherein said fabric has a
front side (600) and a rear side (500), and comprises a base yarn (308),
a mechanical yarn (310), and a pattern yarn (302);

characterized in that it comprises the following steps: [0143] knitting
the pattern yarn (302) on the front side (600) of the fabric; [0144]
inserting the mechanical yarn (312) at a position of 1 to 50, preferably
1 to 20, more preferably 1 to 10 and most preferably 1, 2 or 3 stitches
before the start of a mechanical unit (900) which is produced using the
respective mechanical yarn; [0145] knitting the mechanical yarn (362) on
the rear side of the fabric before the start of the mechanical unit (900)
with the abovementioned number of stitches, together with the base yarn
(308); [0146] knitting the mechanical yarn (312) on the rear side of the
fabric in the mechanical unit (900), except for connecting points where
it is knitted on the front side of the fabric; [0147] knitting the
mechanical yarn (312) on the rear side of the fabric after the mechanical
unit (900) which is produced using the respective mechanical yarn for 1
to 50, preferably 1 to 20, more preferably 1 to 10 and most preferably 1,
2 or 3 stitches, together with the base yarn (308); and [0148]
subsequently cutting off the mechanical yarn (312).

[0149] By using mechanical yarns on the rear side of the fabric, it is for
example possible to introduce variations in elasticity. Knitting
mechanical yarns only locally can result in a significant cost saving,
since such yarns are, for example, only required in well-defined
locations in the mattress tick. Thus, the mechanical yarns may be
provided in a well-defined zone in order to support, for example, the
shoulder or hip. With such a system, a base yarn is alternated with a
mechanical yarn on the dial, with both yarns together completing one line
and overlapping in, for example, 1 to 50, preferably 1 to 20, more
preferably 1 to 10 and most preferably 1, 2 or 3 stitches.

[0150] Item 16: The method according to item 15, which further comprises
knitting with a second pattern yarn (304), in which: [0151] the second
pattern yarn (304) is inserted at a position of 1 to 50, preferably 1 to
20, more preferably 1 to 10 and most preferably 1, 2 or 3 stitches before
the start of a pattern unit (400) which is produced using the respective
second pattern yarn (304) and is knitted on the rear side of the fabric
before the start of the pattern unit (400) for the abovementioned number
of stitches; [0152] the second pattern yarn (304) is subsequently knitted
on the front side of the fabric in the pattern unit (400); [0153] the
second pattern yarn (304) is knitted on the rear side of the fabric after
the pattern unit (400) for 1 to 50, preferably 1 to 20, more preferably 1
to 10 and most preferably 1, 2 or 3 stitches after the end of the pattern
unit; [0154] the second pattern yarn (304) is subsequently cut off.

[0155] In this way, a considerable amount of expensive pattern yarn is
saved, for example compared to the known methods such as for example
described in EP1975294, because expensive pattern yarns are only knitted
in a pattern unit and in the immediate vicinity of a pattern unit.

[0156] Item 17: The method according to any one of items 15 to 16,
characterized in that the knitting process uses a pattern unit and/or a
mechanical unit which comprises more than 12 needles, making it possible
to knit large designs.

[0157] Item 18: The method according to any one of items 15 to 17,
characterized in that the fabric is a non-reversible single-sided knitted
fabric wherein the desired design is knitted on the front side of the
fabric.

[0158] Double jersey knitted fabrics according to the present invention
have a front side and a rear side. By using the rear side as the
technical side and the front side as the aesthetic side with a desired
design, it is possible to produce a plurality of effects. Thus, for
example, an area of relief fabric may be created by knitting an elastic
yarn under tension on the rear side and a non-elastic yarn which is not
under tension on the front side.

[0159] Item 19: The method according to any one of items 15 to 18, in
which the design of the front side (F) of the fabric comprises at least
one area of relief fabric.

[0160] In mattress ticks, relief fabric may be used to form a decorative
pattern. In addition, the relatively voluminous enclosed space in an area
of relief fabric makes it soft to the touch and ensures improved
ventilation.

[0161] Item 20: The method according to any one of items 15 to 19,
characterized in that the loose ends are 0.1 to 5 cm long, are preferably
0.5 cm to 2.5 cm long and are most preferably approximately 1 cm long.

[0162] The loose ends of the mechanical yarns have to have a minimum
length, approximately 0.1 cm, to ensure that the yarns are sufficiently
anchored in the fabric. On the other hand, the loose ends of the yarns
are most preferably not too long, i.e. less than approximately 5 cm, in
order to prevent wasting yarn and to prevent anything from showing
through. Loose ends of approximately 1 cm are a good compromise between
anchoring and preventing anything from showing through or wasting yarn.

[0163] The loose ends of the pattern yarns also have to have a minimum
length, approximately 0.1 cm, to ensure that the yarns are sufficiently
anchored in the fabric. On the other hand, the loose ends of the yarns
are most preferably not too long, i.e. less than approximately 5 cm, in
order to prevent wasting yarn and to prevent anything from showing
through. Loose ends of approximately 1 cm are a good compromise between
anchoring and preventing anything from showing through or wasting yarn.

[0164] Item 21: The method according to any one of items 15 to 20,
characterized in that the fabric is provided with one or more filler
threads which are inserted between the front side and the rear side of
the double jersey knitted fabric.

[0165] These filler threads give volume to the space between the front and
rear side of the double jersey knitted fabric which makes the fabric more
luxurious to the touch and makes it slightly softer. In addition, it
benefits the ventilating properties of the fabric and gives the fabric a
relief effect.

[0166] Item 22: The method according to one of claims 15 to 21,
characterized in that the loose ends are inserted between the rear side
and the front side of the knitted fabric.

[0167] Positioning the loose ends (820, 822) in this way may be
advantageous when it is undesirable for the loose ends (820, 822) to
protrude from the rear side (500) of the fabric (100). This may be the
case, for example, when the rear side (500) is subjected to a
considerable shear load. If such a shear load acts on the loose ends
(820, 822), the fabric (100) might become damaged. In addition, the loose
ends are generally not visible, or hardly at all, on the front side or
rear side of the finished fabric in this way.

[0168] Item 23: The method according to any one of items 15 to 22 for
knitting a mattress tick.

[0169] Item 24: A fabric produced by the method according to any one of
items 15 to 23.

[0170] In some embodiments, the fabric comprises more than one pattern
yarn and/or more than one mechanical yarn.

[0171] By using several mechanical yarns, it is possible to produce a
fabric in which different locations on the rear side have different
mechanical properties. Thus, for example, a fabric may be obtained in
which the elasticity of the rear side varies from location to location.

[0172] In some embodiments, the fabric is provided with one or more filler
threads which are used as filler threads between the front side and the
rear side of the double jersey knitted fabric.

[0173] These filler threads give volume to the space between the front and
rear side of the double jersey knitted fabric which renders the fabric
more luxurious to the touch and also makes it softer. In addition, it
benefits the insulating properties of the fabric.

[0174] Item 25: The present invention also provides a double jersey
knitted fabric (100): [0175] which has a front side (600) and a rear
side (500); [0176] in which the fabric comprises a base yarn (308) which
is knitted on the rear side (500) of the fabric (100), except for
connecting points (240, 242) where the pattern yarn (308) is killed on
the front side (600) of the fabric (100); characterized in that the
fabric comprises a pattern yarn (302), in which: [0177] the pattern yarn
(302) is inserted before the start of a pattern unit (401) which is
produced using the pattern yarn (302); [0178] the pattern yarn (302) is
knitted on the front side (600) of the fabric in the pattern unit which
is produced using said yarn (400); [0179] the pattern yarn (302) is cut
off after the pattern unit (400) produced using said yarn (302).

[0180] Item 26: A double jersey knitted fabric: [0181] in which the
fabric has a front side (600) and a rear side (500); [0182] in which the
fabric comprises a base yarn (308) which is knitted on the rear side
(500) of the fabric (100), except for connecting points (240, 242) where
the base yarn (308) is knitted on the front side of the fabric;
characterized in that the fabric comprises a pattern yarn (304), in
which: [0183] the pattern yarn (304) is inserted before the start of a
pattern unit (400) which is produced using the respective yarn (304);
[0184] the pattern yarn (304) is knitted on both the front side (600) and
the rear side (500) of the fabric in the pattern unit (400); [0185] the
pattern yarn (304) is cut off after the pattern unit (400) produced using
said yarn.

[0186] Item 27: A double jersey knitted fabric: [0187] which has a front
side (600) and a rear side (500); [0188] in which the fabric comprises a
base yarn (308) which is knitted on the rear side (500) of the fabric
(100), except for connecting points (240, 242) where the base yarn (308)
is knitted on the front side of the fabric; characterized in that the
fabric comprises a first pattern yarn (302), a second pattern yarn (304),
and a third pattern yarn (306), in which: [0189] the first pattern yarn
(302) is only knitted on the front side (600) of the fabric in a first
pattern unit (400) produced using the first pattern yarn (302); [0190]
wherein the first pattern yarn (302): [0191] either floats between the
front side (600) and the rear side (500) of the fabric in the zones which
are not produced using the first pattern yarn (302), in particular a
second pattern unit (401) preceding the first pattern unit (400) and a
third pattern unit (402) following the first pattern unit (400); or
[0192] is inserted before the first pattern unit (400) which is produced
using the first pattern yarn (302), is knitted on the front side in the
first pattern unit (400), and is cut off after the first pattern unit;
[0193] the second pattern yarn (304) is inserted before the first pattern
unit (401) which is produced using the second pattern yarn (304); [0194]
the second pattern yarn (304) is knitted on both the front side (600) and
the rear side (500) of the fabric in the second pattern unit (401);
[0195] the second pattern yarn (304) is knitted on the rear side (500) of
the fabric (100) in the first pattern unit (400); [0196] the second
pattern yarn (304) is knitted on both the front side (600) and on the
rear side (500) of the fabric (100) in the third pattern unit (402);
[0197] the second pattern yarn (304) is cut off after the third pattern
unit (402); [0198] the third pattern yarn (306) is knitted in an
identical manner to the first pattern yarn (302).

[0199] Item 28: The double jersey knitted fabric (100) according to any of
items 25 to 27, in which, in addition, a binding yarn (312) is knitted in
together with the respective pattern yarns (302, 304, 306) on the front
side (600) of the fabric (100).

[0200] Item 29: A double jersey knitted fabric (100): [0201] in which
the fabric has a front side (600) and a rear side (500); [0202] in which
the fabric comprises a base yarn (308) which is knitted on the rear side
(500) of the fabric (100), except for connecting points (240) where the
base yarn (308) is knitted on the front side (600) of the fabric (100);
characterized in that [0203] the fabric comprises a first pattern yarn
(302), a second pattern yarn (304), and a binding yarn (312); in which
[0204] the binding yarn (312) is inserted at a position of 1 to 50,
preferably 1 to 20, more preferably 1 to 10 and most preferably 1, 2 or 3
stitches before the start of a pattern unit (400); [0205] the binding
yarn (312) is knitted on the front side of the fabric before the start of
the pattern unit (400) for the abovementioned number of stitches,
together with the first pattern yarn (302) which is knitted before on the
front side (600) of the fabric (100) the start of the pattern unit (400);
[0206] the second pattern yarn (304) is inserted at the start of pattern
unit (400) and the first pattern yarn (302) is cut off; [0207] the
binding yarn (312) is knitted on the front side (600) of the fabric (100)
after the start of the pattern unit (400), together with the second
pattern yarn (304) which is knitted on the front side of the fabric in
said pattern unit; [0208] the binding yarn (312) is knitted on the front
side of the fabric after the end of the pattern unit (400) for the
abovementioned number of stitches, together with the second pattern yarn
(304) which is knitted on the front side (600) of the fabric (100) after
the end of said pattern unit (400); [0209] the binding yarn (312) and the
first pattern yarn (302) are subsequently cut off so that the loose ends
of the binding yarn (312) and the first pattern yarn (302) are 0.1 to 5
cm long, are preferably 0.5 cm to 2.5 cm long, and are most preferably
approximately 1 cm long.

[0210] Item 30: A double jersey knitted fabric (100): [0211] which has a
front side (600) and a rear side (500); [0212] which comprises a base
yarn (308) which is knitted on the rear side (500) of the fabric (100),
except for connecting points (240) where the base yarn (308) is knitted
on the front side (600) of the fabric (100); [0213] which comprises a
first pattern yarn (302), and optionally a second pattern yarn (304) and
a third pattern yarn (306); characterized in that: [0214] the first
pattern yarn (302) is inserted at a position of 1 to 50, preferably 1 to
20, more preferably 1 to 10 and most preferably 1, 2 or 3 stitches before
the start of a pattern unit (400) which is produced using the respective
pattern yarn (302), and is knitted on the rear side of the fabric (100)
before the start of the pattern unit (400) for the abovementioned number
of stitches; [0215] the first pattern yarn (302) is subsequently knitted
on the front side (600) of the fabric in the pattern unit (400); [0216]
the first pattern yarn (302) is knitted on the rear side (500) of the
fabric (100) after a pattern unit (400) for 1 to 50, preferably 1 to 20,
more preferably 1 to 10 and most preferably 1, 2 or 3 stitches after the
end of a pattern unit (400); and [0217] the first pattern yarn (302) is
subsequently cut off; [0218] optionally, the second pattern yarn (304)
and the third pattern yarn (306) are knitted in a way similar to that
described for the first pattern yarn (302) in and around the pattern
units which are produced using said respective yarns.

[0219] Item 31: The fabric according to any one of i25 to 30,
characterized in that the fabric comprises at least one pattern unit
which was made using more than 12 needles, making it possible to knit
large patterns.

[0220] Item 32: The fabric according to any one of items 25 to 31,
characterized in that the fabric is a non-reversible single-sided knitted
fabric wherein the desired design is knitted on the front side of the
fabric. Double jersey knitted fabrics according to the present invention
have a front side and a rear side. By using the rear side as the
technical side and the front side as the aesthetic side with a desired
design, it is possible to produce a plurality of effects. Thus, it is
possible, for example, to create an area of relief fabric by knitting an
elastic yarn at relatively high tension on the rear side and a
non-elastic yarn at relatively low tension on the front side.

[0221] Item 33: The fabric according to any one of items 25 to 32, in
which the design of the front side (F) of the fabric which is knitted
comprises at least one area of relief fabric. In mattress ticks, relief
fabric is currently used to produce a decorative pattern. In addition,
the relatively voluminous enclosed space in an area of relief fabric
makes it soft to the touch and ensures improved ventilation.

[0222] Item 34: The fabric according to any one of items 25 to 33,
characterized in that the loose ends (830, 832) of yarns are 0.1 to 5 cm
long, are preferably 0.5 cm to 2.5 cm long and are most preferably
approximately 1 cm long. The loose ends of the pattern yarns have to have
a minimum length, approximately 0.1 cm, to ensure that the yarns are
sufficiently anchored in the fabric. On the other hand, the loose ends of
the yarns are most preferably not too long, i.e. less than approximately
5 cm, in order to prevent wasting yarn and to prevent anything from
showing through. Loose ends of approximately 1 cm are a good compromise
between anchoring and preventing anything from showing through or wasting
yarn.

[0223] Item 35: The fabric according to any one of items 25 to 34,
characterized in that the fabric comprises one or more filler threads
which are inserted between the front side and the rear side of the double
jersey knitted fabric. These filler threads give volume to the space
between the front and rear side of the double jersey knitted fabric,
rendering the fabric more luxurious to the touch and making it slightly
softer. In addition, it benefits the ventilating properties of the fabric
and gives the fabric a relief effect.

[0224] Item 36: The fabric according to any one of items 25 to 35,
characterized in that the loose ends (830, 832) of yarns are inserted
between the rear side (500) and the front side (600) of the fabric.
Positioning the loose ends (820, 822) in this way may be advantageous
when it is undesirable for the loose ends (820, 822) to protrude from the
rear side (500) of the fabric (100). This may be the case, for example,
when the rear side (500) is subjected to a considerable shear load. If
such a shear load acts on the loose ends (820, 822), the fabric (100)
might become damaged.

[0225] In addition, the loose ends are generally not visible, or hardly at
all, on the front side or rear side of the finished fabric in this way.

[0226] Item 37: A mattress tick comprising the fabric according to any one
of items 25 to 36.

[0227] Item 38: A method for producing a fabric according to any one of
items 25 to 37.

[0228] Item 39: A fabric knitted on a double jersey, double jacquard
circular knitting machine: [0229] which has a front side (600) and a
near side (500); [0230] which comprises a base yarn (308), a mechanical
yarn (310), a pattern yarn (302); characterized in that: [0231] the
pattern yarn (302) is knitted on the front side (600) of the fabric;
[0232] the mechanical yarn (312) is inserted at a position of 1 to 50,
preferably 1 to 20, more preferably 1 to 10 and most preferably 1, 2 or 3
stitches before the start of a mechanical unit (900) which is produced
using the respective mechanical yarn; [0233] the mechanical yarn (362) is
knitted on the rear side of the fabric before the start of the mechanical
unit (900) for the abovementioned number of stitches, together with the
base yarn (308); [0234] the mechanical yarn (312) is knitted on the rear
side of the fabric in the mechanical unit (900), except for connecting
points where it is knitted on the front side of the fabric; [0235] the
mechanical yarn (312) is knitted on the rear side of the fabric after the
mechanical unit (900) which is produced using the respective mechanical
yarn, for 1 to 50, preferably 1 to 20, more preferably 1 to 10 and most
preferably 1, 2 or 3 stitches, together with the base yarn (308); and
[0236] the mechanical yarn (312) is subsequently cut off.

[0237] By using mechanical yarns on the rear side of the fabric, it is for
example possible to introduce variations in elasticity. Knitting
mechanical yarns only locally can result in a significant cost saving,
since such yarns are, for example, only required in well-defined
locations in the mattress tick. Thus, the mechanical yarns may be
provided in a well-defined zone in order to support, for example, the
shoulder or hip. With such a system, a base yarn is alternated with a
mechanical yarn on the dial, with both yarns together completing one line
and overlapping in, for example, 1 to 50, preferably 1 to 20, more
preferably 1 to 10 and most preferably 1, 2 or 3 stitches.

[0238] Item 40: The fabric according to item 39 which comprises a second
pattern yarn (304), in which: [0239] the second pattern yarn (304) is
inserted at a position of 1 to 50, preferably 1 to 20, more preferably 1
to 10 and most preferably 1, 2 or 3 stitches before the start of a
pattern unit (400) which is produced using the respective second pattern
yarn (304) and is knitted on the rear side of the fabric before the start
of the pattern unit (400) for the abovementioned number of stitches;
[0240] the second pattern yarn (304) is subsequently knitted on the front
side of the fabric in the pattern unit (400); [0241] the second pattern
yarn (304) is knitted on the rear side of the fabric after the pattern
unit (400) for 1 to 50, preferably 1 to 20, more preferably 1 to 10 and
most preferably 1, 2 or 3 stitches after the end of the pattern unit;
[0242] the second pattern yarn (304) is subsequently cut off.

[0243] Item 41: The fabric according to any one of items 39 to 40,
characterized in that the fabric comprises a pattern unit and/or a
mechanical unit which consists of more than 12 needles, making it
possible to knit large designs.

[0244] Item 42: The fabric according to any one of items 39 to 41,
characterized in that the fabric is a non-reversible single-sided knitted
fabric wherein the desired design is knitted on the front side of the
fabric. Double jersey knitted fabrics according to the present invention
have a front side and a rear side. By using the rear side as the
technical side and the front side as the aesthetic side with a desired
design, it is possible to produce a plurality of effects. Thus, it is
possible, for example, to create an area of relief fabric by knitting an
elastic yarn at relatively high tension on the rear side and a
non-elastic yarn at relatively low tension on the front side.

[0245] Item 43: The fabric according to any one of items 39 to 42, in
which the design of the front side (F) of the fabric comprises at least
one area of relief fabric. In mattress ticks, relief fabric is currently
used to produce a decorative pattern. In addition, the relatively
voluminous enclosed space in an area of relief fabric makes it soft to
the touch and ensures improved ventilation.

[0246] Item 44: The fabric according to any one of items 39 to 43,
characterized in that the loose ends are 0.1 to 5 cm long, are preferably
0.5 cm to 2.5 cm long and are most preferably approximately 1 cm long.
The loose ends of the mechanical yarns have to have a minimum length,
approximately 0.1 cm, to ensure that the yarns are sufficiently anchored
in the fabric. On the other hand, the loose ends of the yarns are most
preferably not too long, i.e. less than approximately 5 cm, in order to
prevent wasting yarn and to prevent anything from showing through. Loose
ends of approximately 1 cm are a good compromise between anchoring and
preventing anything from showing through or wasting yarn.

[0247] The loose ends of the pattern yarns also have to have a minimum
length, approximately 0.1 cm, to ensure that the yarns are sufficiently
anchored in the fabric. On the other hand, the loose ends of the yarns
are most preferably not too long, i.e. less than approximately 5 cm, in
order to prevent wasting yarn and to prevent anything from showing
through. Loose ends of approximately 1 cm are a good compromise between
anchoring and preventing anything from showing through or wasting yarn.

[0248] Item 45: The fabric according to any one of items 39 to 44,
characterized in that the fabric is provided with one or more filler
threads which are inserted between the front side and the rear side of
the fabric. These filler threads give volume to the space between the
front and rear side of the double jersey knitted fabric which renders the
fabric more luxurious to the touch and makes it slightly softer. In
addition, it benefits the ventilating properties of the fabric and gives
the fabric a relief effect.

[0249] Item 46: The fabric according to any one of items 39 to 45,
characterized in that the loose ends are inserted between the rear side
and the front side of the knitted fabric. Positioning the loose ends
(820, 822) in this way may be advantageous when it is undesirable for the
loose ends (820, 822) to protrude from the rear side (500) of the fabric
(100). This may be the case, for example, when the rear side (500) is
subjected to a considerable shear load. If such a shear load acts on the
loose ends (820, 822), the fabric (100) might become damaged.

[0250] In addition, the loose ends are generally not visible, or hardly at
all, on the front side or rear side of the finished fabric in this way.

[0251] Item 47: A mattress tick comprising the fabric according to any one
of items 39 to 46.

[0252] Item 48: A method for producing a fabric according to any one of
items 39 to 47.

[0253] Item 49: In a further aspect, the present invention encompasses a
double jersey, double jacquard circular knitting machine [0254] which
comprises a cylinder (C) and a dial (D) [0255] which is provided with one
or more yarn selection mechanisms [0256] in which the double jersey,
double jacquard circular knitting machine is suitable for knitting a
double jersey knitted fabric according to any one of items 24 or 30 to
37, or a double jersey knitted fabric produced according to the method
according to any one of items 15 to 23; [0257] and in which: [0258]
each yarn selection mechanism is provided with a yarn-cutting device;
[0259] each yarn selection mechanism is configured to be able to perform
a yarn change at any position in the double jersey knitted fabric.

[0260] On a circular knitting machine according to this aspect of the
present invention, it is possible to knit double jersey knitted fabrics
according to other aspects of the present invention in an efficient
manner.

[0261] Item 50: In yet a further aspect, the present invention encompasses
a double jersey, single jacquard circular knitting machine [0262] which
comprises a cylinder (C) and a dial (D) [0263] which is provided with one
or more yarn selection mechanisms [0264] which is suitable for knitting
a double jersey knitted fabric according to any one of items 14, 25 to 29
or 31 to 37, or a double jersey knitted fabric made according to the
method according to any one of items 1 to 13; [0265] and in which:
[0266] each yarn selection mechanism is provided with a yarn-cutting
device; [0267] each yarn selection mechanism is configured to be able to
perform a yarn change at any position in the double jersey knitted
fabric.

[0268] In a particular embodiment of item 49 or 50, said yarn selector is
capable of introducing, feeding and cutting one or more yarns at any
random position of the dial. This implies that at any random position of
the dial, the dial needles would either be able to be temporarily
retracted in said random position to allow the yarn selector to feed the
yarn, or that the yarn selector would be able to temporarily move in the
proximity of the dial needles to feed the yarn to said random position.

[0269] On a circular knitting machine according to this aspect of the
present invention, it is possible to knit double jersey knitted fabrics
according to other aspects of the present invention in an efficient
manner.

[0270] In accordance with items 49 and 50, the yarn selectors can comprise
a yarn feeding, clamping and cutting unit.

[0271] This makes it possible to feed the pattern or mechanical yarn to
the needles by the respective yarn selector at a position of 1 to 50,
preferably 1 to 20, more preferably 1 to 10 and most preferably 1, 2 or 3
stitches before the start of the pattern unit, [0272] following which
the yarn is first knitted in on the rear side of the fabric by the
needles of the dial for the number of stitches mentioned, [0273]
following which the yarn is knitted in by the needles of the cylinder on
the front side of the fabric to form the pattern unit, and finally,
[0274] following which the yarn is again knitted in by the needles of the
dial on the rear side of the fabric for the number of stitches mentioned.
Providing or feeding the yarns by the yarn selector may also be assisted
by the clamping unit which may clamp the yarn before it is inserted and
subsequently immediately release it, as soon as the yarn has been caught
by the needles of the dial; [0275] the yarn is subsequently taken to the
cutting unit by the yarn selector and the yarn can e.g. be clamped by the
clamping unit and cut off by the cutting unit. Typically, this produces a
loose end having a length of approximately 0.1 to 5 cm, preferably 0.5 cm
to 2.5 cm, and most preferably approximately 1 cm, which is inserted
between the knitted fabrics of the front and rear side.

[0276] Although it is unusual, it is possible in any of the method aspects
14 to 22 in which a double jersey double jacquard circular knitting
machine is used, the fabrics which are produced thereby or the fabrics
described in any of the aspects 23, 28, 37-45, for the front side of the
fabric to be knitted alternatively on the dial and the rear side to be
knitted on the dial. The respective aspects can be modified by someone
skilled in the art in a manner completely analogously to the
above-described aspects, in which the respective pattern yarns (302, 304,
306) are inserted, knitted and/or cut off on the dial and in which the
base yarn (308) and/or mechanical yarn (310) is substantially inserted,
knitted and/or cut off on the cylinder analogously to the above-described
aspects. The direction of rotation of the circular knitting machine is
not limited either, but is shown in all examples and embodiments
described herein as being counterclockwise for the sake of simplicity
(the knitting pattern runs from left to right). Analogously, the person
skilled in the art may modify the operation and the knitting patterns in
such a way that the circular knitting machine is able to rotate
clockwise, if required.

DESCRIPTION OF THE FIGURES

[0277] FIG. 1 shows a specific embodiment of a fabric (100) according to
the present invention.

[0278] FIG. 2 shows a specific embodiment of a knitting pattern (110) for
a fabric (100) according to the present invention which comprises four
different yarns (300), knitted on a double jersey, double jacquard
circular knitting machine with 4 knitting systems (001-004).

[0279] FIG. 3 shows a specific embodiment of a knitting pattern (111) for
a fabric (100) according to the present invention which comprises three
different yarns (308, 310, 302), in which the knitting pattern (111)
comprises instructions for producing a mechanical unit (900).

[0280] FIG. 4 shows a specific embodiment of a knitting pattern (112) for
a fabric (100) according to the present invention which comprises four
different yarns (308, 302, 304, 306), knitted on two systems (001, 002).

[0281] FIG. 5 shows a specific embodiment of the start of a pattern unit
in a knitting pattern (113) for a fabric (100) according to the present
invention which comprises four different yarns (308, 302, 312, 304),
knitted on two systems.

[0282] FIG. 6 shows a combination of a number of different specific
embodiments according to the present invention.

[0283] FIG. 7 shows a specific embodiment of the start of a pattern unit
in a knitting pattern for a fabric (100) according to the present
invention which comprises three different yarns (308, 302, 304), knitted
on two systems.

[0284] FIG. 8 shows a specific embodiment of a knitting pattern (117) for
a fabric (100) according to the present invention which comprises four
yarns (300), knitted on four systems.

[0285] FIG. 9 shows a specific embodiment of a knitting pattern (118) for
a fabric (100) according to the present invention which comprises four
yarns (302, 304, 306, 308), knitted on four systems.

[0286] FIG. 10 shows a specific embodiment of a knitting pattern (119) for
a fabric (100) according to the present invention which comprises four
yarns (300), knitted on four systems.

DETAILED DESCRIPTION

[0287] As used below in this text, the singular forms, "the" include both
the singular and the plural, unless the context clearly indicates
otherwise.

[0288] The terms "comprise", "comprises" as used below are synonymous with
"including", "include" or "contain", "contains" and are inclusive or open
and do not exclude additional unmentioned parts, elements or method
steps. The terms "comprise", "comprises" include the term "contain".

[0289] The enumeration of numeric values by means of ranges of figures
comprises all values and fractions in these ranges, as well as the cited
end points.

[0290] The term "approximately" as used when referring to a measurable
value, such as a parameter, an amount, a time period, and the like, is
intended to include variations of +/-10% or less, preferably +/-5% or
less, more preferably +/-1% or less, and still more preferably +/-0.1% or
less, of and from the specified value, in so far as the variations apply
to the invention disclosed herein. It should be understood that the value
to which the term "approximately" refers per se has also been disclosed.

[0291] All references cited in this description are hereby deemed to be
incorporated in their entirety by way of reference.

[0292] Unless defined otherwise, all terms disclosed in the invention,
including technical and scientific terms, have the meaning which a person
skilled in the art usually gives them. For further guidance, definitions
are included to further explain terms which are used in the description
of the invention.

[0293] The present invention provides a method to achieve cost savings
without loss of quality in the field of double jersey knitted fabrics, in
particular double jersey knitted mattress ticks. The invention
furthermore provides a fabric produced by this method and the use of a
double jersey, preferably double jacquard, circular knitting machine in
such a method.

[0294] Thus, the present invention for example provides a method for
knitting a double jersey fabric in which expensive, aesthetic pattern
yarns are inserted into a knitted fabric a few stitches before a pattern
unit. These pattern yarns are, for example, anchored on the rear side of
the fabric before the start of the pattern unit using a few stitches. In
a pattern unit, the expensive pattern yarns are subsequently knitted on
the front side of the fabric and after the pattern unit, the expensive
pattern yarns are knitted for anchoring on the rear side of the fabric
for a few stitches before being cut off. The loose ends of the pattern
yarns are preferably only approximately one centimetre long, as a result
of which the risk of anything showing through is eliminated. In addition,
a significant amount of expensive pattern yarn is saved compared to the
method as described, for example, in EP1975294 because expensive pattern
yarns are only knitted in a pattern unit and in the immediate vicinity of
a pattern unit.

[0295] An analoguous method makes a saving on mechanical yarn possible by
inserting mechanical yarn only a few stitches before a mechanical unit
(or pattern) and cutting off the mechanical yarn a few stitches after the
mechanical unit.

[0296] Generally, any lay-in threads or filler threads (lay-in yarn or
filler yarn) cover the loose ends of the cut-off pattern yarn, because
these are anchored on the rear side of the fabric. As a result thereof,
any risk of anything showing through in the region of the fabric where
the loose ends have been inserted between the front and the rear side of
the fabric is eliminated.

[0297] For the sake of completeness, it should be noted that, in the prior
art, with double jersey knitted fabrics, the intarsia technique is being
used to knit yarns only in a specific location of a fabric. In that
sense, this technique is a technology which has the same objective as the
present invention. However, the intarsia technique requires a much more
expensive machine as the machine has to rotate both clockwise and
anticlockwise during the knitting process (return-knitting). Because this
involves constant changes in direction, the knitting process proceeds at
a much slower speed, resulting in lower productivity compared to the
present invention. Finally, with the intarsia technique the freedom of
design is also much more limited than with a knitting technique according
to the present invention. In particular, it is not easy to produce
asymmetrical designs by means of the intarsia technique.

[0298] In the subsequent paragraphs, the operation of the cutting device
and the yarn selector is illustrated for pattern yarns and mechanical
yarns. The operation applies analogously to binding yarns, mutatis
mutandis. In order to describe the operation of the cutting device and
yarn selector, the selection of pattern and/or mechanical yarns on a
double jacquard circular knitting machine is described below by way of
non-limiting example. The person skilled in the art will understand that
such systems can also be installed on e single jacquard circular knitting
machine, in which case the operation is modified in accordance with the
methods for such equipment as described herein.

[0299] 1) The pattern or mechanical yarn to be selected is fed to the
needles by the respective yarn selector at a position of 1 to 50,
preferably 1 to 20, more preferably 1 to 10 and most preferably 1, 2 or 3
stitches before the start of the respective pattern unit, following which
the yarn is first knitted in by the needles of the dial for the mentioned
number of stitches on the rear side of the fabric, the yarn is
subsequently knitted in by the needles of the cylinder on the front side
of the fabric in order to produce the pattern unit and, finally, the yarn
is again knitted in by the needles of the dial for the mentioned number
of stitches on the rear side of the fabric. Providing or feeding the
yarns by the yarn selector may also be aided by the clamping unit of the
cutting device which can clamp the yarn for insertion and then
immediately release the yarn once it has been carried along by the
needles of the dial;

[0300] 2) When it has past the respective pattern unit, the yarn to be cut
off is subsequently taken to the cutting device by the yarn selector and
the yarn is clamped by the clamping unit and cut off by the cutting unit.
Typically, a loose end having a length of approximately 0.1 to 5 cm,
preferably 0.5 cm to 2.5 cm, and most preferably approximately 1 cm, is
formed in this case, which is tucked away between the knitted fabrics of
the front and rear side.

[0301] In a specific embodiment, the present invention comprises a double
jersey knitted fabric (100), as illustrated in FIG. 1. The double jersey
knitted fabric (100) has a rear side (500) and a front side (600),
knitted by one or more pattern yarns (302, 304, 306). The front side
(600) of the fabric (100) is knitted on the cylinder (C) and the rear
side (500) of the fabric (100) is knitted on the dial (D) by a base yarn
(308). Between the front side (600) of the fabric (100) and the rear side
(500) of the fabric (100), there is an enclosed space, the inner side
(700) of the fabric (100). The inner side (700) of the fabric (100)
optionally contains filler threads (710) which are intended to give
volume to the fabric (100). This improves the ventilation of the fabric
(100) and renders the fabric (100) softer to the touch. The yarns (302,
304, 306) used to knit a pattern unit (400) on the front side (600) of
the fabric (100) are inserted a few stitches before the pattern unit
(220) on the rear side of the fabric. The pattern yarns (302, 304, 306)
used to knit a pattern unit (400) on the front side (600) of the fabric
(100) are cut off after a few stitches which are knitted behind the
pattern unit (400) on the rear side of the fabric. These yarns (302, 304,
306) are inserted and cut off in such a way that loose ends (820, 822)
are created. These loose ends (820, 822) are positioned and/or fixed on
the inner side (700) of the fabric (100) so that they are situated
between the filler threads (710) and the rear side (500) of the fabric
(100).

[0302] Positioning the loose ends (820, 822) in this way may be
advantageous when it is undesirable for the loose ends (820, 822) to
protrude from the rear side (500) of the fabric (100). This may be the
case, for example, when the rear side (500) is subjected to a
considerable shear load. If such a shear load acts on the loose ends
(820, 822), the fabric (100) might become damaged.

[0303] In a further specific embodiment, the present invention comprises a
method for knitting a double jersey fabric according to the present
invention as well as the knitted fabric itself, as represented in the
form of knitting pattern (110) in FIG. 2. The knitting pattern (110)
comprises instructions for knitting four yarns (300) on the dial (D) and
the cylinder (C) of a double jacquard, double jersey circular knitting
machine. The rear side of the fabric is knitted on the dial (D) and the
front side of the fabric is knitted on the cylinder (C). The yarns (300)
are subdivided into two types of yarn. Base yarns (308) are only knitted
on the rear side of the fabric (100), except for connecting points (240)
between the rear side (500) and the front side (600) of the fabric (100)
in a pattern unit (400). In this example, the pattern unit (400) is
designed as a relief fabric. Pattern yarns (302, 304, 306) are only
knitted on the front side of the fabric, except for a number of, for
example three, stitches (220, 230) adjacent to a pattern unit (400) which
are knitted on the rear side of the fabric. These few stitches (220, 230)
serve as anchoring points between the front and rear side of the fabric
(100). The pattern yarns (302, 304, 306) are inserted by a yarn selection
mechanism shortly before their respective pattern unit (400) which is
being knitted using the respective yarn(s) and they are cut off by a
cutting device shortly after the respective pattern unit (400). This
results in loose ends (830, 832). Inserting and cutting off the pattern
yarns (302, 304, 306) just before and after the pattern unit (400) has
various positive effects. Firstly, less pattern yarn is used, resulting
in a significant saving in material and costs. Secondly, a
showing-through effect is prevented which could occur if the pattern
yarns (302, 304, 306) floated over long distances between the pattern
units (400). Thirdly, it is possible to produce knitted fabrics which are
more lightweight while retaining the same quality.

[0304] In a further specific embodiment, the present invention comprises a
knitting pattern (111) as illustrated in FIG. 3. The knitting pattern
(111) comprises instructions for knitting three yarns (308, 310, 302).
Two yarns, one base yarn (308) and a mechanical yarn (310) are
alternately knitted on the rear side, except in connecting points, and
have a different elasticity. Thus, a fabric is produced which is elastic
in a certain area (the mechanical unit) and is not elastic in another
area, or to a lesser degree. Knitting of the base yarn (308) on the dial
(D) starts according to the known double jersey technique. The mechanical
yarn (310) is inserted a few stitches before the mechanical unit (900)
and knitted on the dial for a few stitches together with the base yarn
(308), after which the base yarn is cut off. A few stitches before the
end of the mechanical unit (900), the base yarn is inserted again and
knitted on the dial together with the mechanical yarn (310), after which
the mechanical yarn is cut off. Thereafter, knitting is continued with
the base yarn on the dial. In this way, a continuous line is formed in
the knitted fabric on the dial which alternately contains a base yarn or
a mechanical yarn, and only overlaps for a few stitches. The two yarns
(308, 310) also comprise loose ends (831, 833) which are tucked away
between the front side and rear side. The front side of the knitted
fabric is knitted simultaneously with, for example, pattern yarns (302,
304, 306) on the cylinder (C). This process may be combined with a
technique in which pattern yarns are inserted and cut off to form the
pattern as described above.

[0305] In a specific embodiment, the present fabric comprises a knitting
pattern (112), knitted on two systems (001, 002), for knitting three or
more yarns (308, 302, 304, 306). A base yarn (308) is knitted in a first
system on the dial (D) of a double jersey, single jacquard circular
knitting machine, except for connecting points (240) where the front side
and the rear side of the fabric are connected to each other by means of
base yarn (308). A first and a second pattern yarn (302, 304) are knitted
on the cylinder (C) of the circular knitting machine (FIG. 4). Pattern
yarn (302) is knitted in pattern unit (401) and yarn (304) is knitted in
the subsequent pattern unit (400). Pattern yarn (304) is inserted at the
start of pattern unit (400) in which the respective yarn is knitted.
Pattern yarn (302) is cut off at the end of the preceding pattern unit
(401). In the transition regions between the successive pattern units
(400 and 401), a binding yarn (312) is knitted together by means of yarns
(302 and 304) to form double stitches by means of a plating technique
(French: vanisage). The binding yarn may optionally be a thinner yarn
than the pattern yarn. The term "thinner" as used herein means that the
binding thread (312) has a diameter which is preferably smaller than that
of the pattern yarns (302, 304) with which the binding thread is knitted
together. A binding thread (312) which has approximately the same
diameter as pattern yarns (302, 304) may also be used. In this way,
pattern yarns (302, 304) are mechanically anchored at the transition
between two pattern units (401 and 400). A similar system can be used for
a further pattern yarn (306) with which a subsequent pattern unit (402)
is knitted.

[0306] In a further specific embodiment, the present invention comprises
the start of a pattern unit, represented as knitting pattern (113) in
FIG. 5, for a fabric (100) according to the present invention. The
knitting pattern comprises four different yarns (308, 302, 304, 306),
knitted on two systems. Base yarn (308) is knitted on the rear side of
the fabric. Pattern yarn (302) is knitted on the front side, just before
a pattern unit which is knitted by means of a second pattern yarn (304).
Pattern yarns (302) and (304) are anchored to each other by means of a
binding yarn (312) which is knitted together with first pattern yarn
(302) for a number of stitches, for example three stitches, before the
start of the pattern unit which is produced using the second pattern yarn
(304). The binding yarn (312) is also knitted together with the second
pattern yarn (304) during the first stitches of the pattern unit which is
produced using pattern yarn (304). The number of stitches is obviously
not limited to the number of stitches mentioned here, but may also be,
for example 1, 2, 3, 4, 5 or more stitches, such as for example 1 to 10,
1 to 20 or 1 to 50 stitches.

[0307] In a further specific embodiment, a combination of different
abovementioned aspects and embodiments is illustrated. In this specific
embodiment, the present invention comprises a knitting pattern (140) for
a fabric (100), as illustrated in FIG. 6. The fabric is knitted by means
of four systems (001, 002, 003, 004). On system (001), a base yarn (308)
is knitted on the dial, except for connecting points which are knitted on
the cylinder. In systems (002, 003, 004), aesthetic pattern yarns (302a,
302b, 304, 306a, 306b) are knitted which are mainly knitted on the front
side, except for anchoring points which are knitted on the dial. The
knitting pattern (140) comprises instructions for knitting different
pattern units (480, 481, 482, 483, 484, 485, 486) by means of different
yarns (302a, 302b, 304, 306a, 306b). Pattern unit (480) is produced using
pattern yarn (302a) and comprises an anchoring point (240) produced using
base yarn (308). Pattern yarn (302a) is not cut off after pattern unit
(480), but remains floating between the cylinder and the dial to be
picked up again by the needles of the cylinder in pattern unit (482).
Pattern unit (481) is produced using yarn (306a). Pattern yarn (306a) is
only fixed on the dial by means of a few, for example two, stitches after
inserting the yarn and a few, for example two, stitches before cutting
the pattern yarn (306a). Pattern unit (482) is produced using pattern
yarn (302a) and comprises one connecting point which is produced using
base yarn (308). Pattern yarn (302a) is knitted on the dial after pattern
unit (482) for a few, for example two, stitches and is subsequently cut
off. Pattern unit (483) is produced using pattern yarn (306b). Pattern
yarn (306b) is inserted before pattern unit (483), is knitted on the dial
for a few, for example two, stitches before and after pattern unit (483)
and is subsequently cut off. Pattern unit (484) is produced using pattern
yarn (302b). Pattern yarn (302b) is inserted before pattern unit (484)
and knitted on the dial for a few, for example two, stitches before
pattern unit (484). After pattern unit (484), pattern yarn (302b) floats
between the cylinder and the dial, except for connecting points on the
dial. Pattern unit (485) is produced using a third pattern yarn (304).
Third pattern yarn (304) is inserted before pattern unit (485), is
knitted on the dial for a few, for example two, stitches before and after
pattern unit (485) and floats after pattern unit (485) between the
cylinder and the dial or can be cut off. Pattern unit (486) is produced
using pattern yarn (302b). In this example, pattern yarns 302a and 302b
are different parts of the same yarn. The second pattern yarns 306a and
306b are also different parts of the same yarn. Alternatively, the first,
second and third pattern yarns may also in each case be composed of a
different type (colour, form, thickness, finish, . . . ) of pattern yarn.
The number of stitches is obviously not limited to the number of stitches
mentioned herein, but may be, for example 1, 2, 3, 4, 5 or more stitches,
such as for example 1 to 10, 1 to 20 or 1 to 50 stitches.

[0308] In a further specific embodiment, the present invention comprises
the start of a pattern unit represented as knitting pattern (114) in FIG.
7 for a fabric (100) according to the present invention. The knitting
pattern comprises three different yarns (308, 302, 304), knitted on two
systems. Base yarn (308) is knitted on the rear side of the fabric,
except for connecting points (240, 242) at the transition between a first
area where pattern yarn (302) is knitted on the front side of the fabric,
and a second area where yarn (304) is knitted on the front side of the
fabric. Connecting points (241, 242) ensure that yarns (302) and yarn
(304) are anchored.

[0309] In a further specific embodiment, the present invention comprises a
knitting pattern (117) for knitting a fabric (100) by means of four yarns
(300), knitted by means of four systems. First base yarn (308) is only
knitted on the dial (D), except for connecting points (240, 242). A
second pattern yarn (302) is only knitted on the cylinder (C) in a
pattern unit (400) which is produced using said second yarn. Pattern yarn
(302) is inserted at the start of pattern unit (400) and is cut off after
the end of pattern unit (400). Another, second, pattern yarn (304) is
knitted in the preceding and subsequent pattern units (401 and 402,
respectively), both on the cylinder (C) and on the dial (D). In pattern
unit (400), the second pattern yarn (304) is only knitted on the dial
(D). A further pattern yarn (306) may be knitted in the same manner as
the third yarn (302), but on another knitting system (cf. FIG. 8).

[0310] In a further specific embodiment, the present invention comprises a
knitting pattern (118) for knitting a fabric (100) by means of at least 2
yarns (300), knitted by means of at least 2 knitting systems. First base
yarn (308) is only knitted on the dial (D), except for connecting points
(240, 241). A second pattern yarn (304) is inserted before the start of a
pattern unit (400) which is produced using said respective pattern yarn
(304). This pattern yarn (304) is knitted on both the front side (600)
and the rear side (500) of the fabric in the respective pattern unit
(400) and is cut off after the pattern unit (cf. FIG. 9). Second pattern
yarn (302) and optionally third pattern yarn (306) are only knitted on
the front side of the fabric if three or four knitting systems are being
used.

[0311] In a further specific embodiment, the present invention comprises a
knitting pattern (119) for knitting a fabric (100) by means of four yarns
(300), knitted by means of four knitting systems. Base yarn (308) is only
knitted on the dial (D), except for connecting points (240, 242). Pattern
yarn (302) is only knitted on the cylinder (C) in a pattern unit (400)
which is produced using this second yarn. This pattern unit is preceded
by a first pattern unit (401) and followed by a third pattern unit (402).
Pattern yarn (302) floats between the front side (600) and the rear side
(500) of the fabric in the preceding (first) pattern unit (401) and the
subsequent (third) pattern unit (402) which is not produced using the
pattern yarn (302). Alternatively, the pattern yarn (302) may be inserted
before the pattern unit (400) and may be cut off after the first pattern
unit (401), analogous to the embodiment described in FIG. 8. Another
pattern yarn (304) is inserted, for example, at the start of first
pattern unit (401) and is cut off after the end of the third pattern unit
(402) and is knitted on both the cylinder (C) and the dial (D) in the
preceding and subsequent pattern units (401 and 402, respectively). In
the first pattern unit (400), the third yarn (304) is only knitted on the
dial (D). A third pattern yarn (306) may be knitted in the same way as
the third yarn (302) on another knitting system (cf. FIG. 10).